Tool Box Pencil Preparation and Turning

29380© Rockler Companies Inc. 2012

Upper Tube Lower TubeWood Spacer

NutTool Box Pencil Bushing Set

Mandrel “A” Threaded end

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Mandrel “A” Setup:

Adjustable Mandrel Setup:

Decorative Ring

Upper Tube Lower TubeAdjustable Mandrel “A” Threaded endDecorative Ring

NutTool Box Pencil Bushing Set

Blank Preparation1. Drill the blanks with an 11mm drill bit at a speed of 900 to 1200 RPM.2. Polish the Brass Tubes with 220 grit sandpaper to remove oxidation and roughen the Tubes for better adhesion. This can be done by hand or by chucking them in a drill press or portable hand drill.3. Prepare to glue with medium CA (cyanoacrylate) glue or two-part fast drying epoxy.4. Apply the glue to the outside of the Lower Tube with a liberal amount around the end that is inserted first. Do not apply glue to the inside of the blank, as this will cause the glue to get inside the Brass Tube and ruin it. Note: Make sure the Threaded End of the Lower Tube is opposite of the “x” mark for grain orientation.5. Method 1: Apply the glue to the outside of the Upper Tube with a liberal amount around the end that is inserted first. Insert the Upper Tube into the end of the blank cut to 121⁄32"

long. Begin from the end that will become the end of the pen, opposite where you have marked your “x” for grain orientation. Push in the Tube until it is flush with the center of the pen, opposite the entry point. There will be a portion of the Upper Tube exposed for the Decorative Ring. Wipe off any excess glue on the ends of the blank and allow the glue to dry. Method 2: Glue the Upper Tube into the blank using the same process as the Lower Tube.6. Using a barrel trimmer, disk, or belt sander, trim the ends of the Lower Blank until you can just see the bright brass ends of the Tube. The faces of the ends must be perpendicular to the Brass Tube and parallel with each other. It is imperative to match the length of the trimmed blank to the original length of the Brass Tube and that the inside of the Brass Tube is clean and free of any glue. Method 2: Trim the Upper Blank using the same process as the Lower Blank.

Turning the Blanks1. Assemble the blanks on the mandrel with the bushings placed as shown in the picture above. Keep the grain orientation of the blanks in line when mounting. Each bushing has a step that is designed to be inserted into the Brass Tubes for stability while turning, as the inner diameter of the tubes is larger than the mandrel. Note that all of the bushings are the same size. Method 1: The bare portion of the tube (for the Decorative Ring) should be next to the bushing nearest the morse taper, as shown in the diagram above.2. Tighten the tailstock and then tighten the mandrel nut that holds the blanks. Do not over-tighten the tailstock or mandrel nut as this may cause the mandrel to flex, causing the blanks to go out of round.3. Turn the blanks to the desired shape, making sure that the surfaces next to the bushings are turned to the same diameter as the bushings.

Method 2: Turn off the lathe. Measure 1/8" from the Cap end of the Upper Tube and make a definitive mark. Using a sharp parting tool, remove all of the wood from the Cap end of the Upper Tube to the 1/8" mark. Be very careful not to damage the Brass Tube. The blank next to the Brass Tube should be 13mm in diameter (the same as the bushing).4. After turning, sand the surfaces in progressive steps of 220, 400, 600, and 1000 grit. If a higher finish is desired, micromesh sandpaper may be used.5. Apply the finish of choice and polish.6. Remove the blanks from the mandrel, keeping the blank orientation and grain patterns in line.

Method 1Cut the Lower Blank about 1/8" longer than the Brass Tube to allow for “blow-out” or hole elongation. Cut the Upper Blank to exactly 121⁄32" long. This will leave part of the Brass Tube exposed. Maintain grain orientation of the two blanks for turning by placing an “x” on either side of the cut line.

Method 2Cut the blanks about 1/8" longer than the Brass Tubes to allow for “blow-out” or hole elongation. Maintain grain orientation of the two blanks for turning by placing an “x” on either side of the cut line. Later, you will need to turn a portion of the wood blank down to the Brass Tube on the lathe.

AssemblyRead the assembly instructions completely before assembly.1. Press the Center Coupler into the unthreaded end of the Lower Tube. 2. Press the Decorative Ring onto the exposed brass of the Upper Tube. If the fit is loose, a drop of CA (cyanoacrylate) glue may be used to secure the ring.3. Align the grain of the Upper and Lower blanks, then press the Upper Tube onto the Center Coupler. Take care not to use excessive force as this could cause the assembly to buckle.4. Slide the Stop Ring onto the end of the Lead Shaft closest to the Ridges. The Stop Ring should contact the Ridges approximately 3/4" from the end of the Lead Shaft. 5. Insert the narrow end of the Lead Holder into the narrow end of the Tip. The chamfered end of the Lead Holder should extend 1/2" past the threaded end of the Tip.

6. Insert the Spring onto the shorter end of the Lead Shaft until it contacts the Stop Ring.7. Insert the tapered end of the Lead Holder into the Spring and press it into the Lead Shaft. While pressing, you will also be compressing the Spring by 1" and it will be very tight. If the Spring does not look like it will compress that far, check to make sure the Stop Ring is on the shorter side of the Ridges on the Lead Shaft.8. Insert the Lead Shaft assembly into the Lower Tube and thread the Tip into place.9. Insert the Lead into the Lead Shaft through the Upper Tube, then push the Sharpener Coupler into place.10. To sharpen the Lead, unscrew the Sharpener from the Sharpener Coupler and sharpen the Lead point.

Reordering Information Stock #Tool Box Pencil Kit ...............................................293807mm Mandrel “A” with #2 Morse Taper ...............435377mm Mandrel “A” with #1 Morse Taper ...............39389Adjustable 7mm Mandrel “A” with #2 Morse Taper ............................................25581Tool Box Pencil Bushing Set ................................2686211mm Drill Bit .......................................................30913

Tool Box Pencil Assembly

29380 - Rev 09/12

WARN

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alifornia to cause cancer and birth defects or other reproductive harm

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ash hands after handling.

Made in C

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Distributed by R

ockler C

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© 2012 R

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Sharpener Sharpener Coupler

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